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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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Modifications to assembly procedures for C-core transformers virtually eliminates changes in core end gaps due to temperature cycling during impregnation and potting stages, thus stabilizing magnetization properties of core.
A servo controlled target replica, and a surface bearing a computer generated line drawing of an object are individually viewed by separate television cameras allowing a two-dimensional composite of the target replica and the object to be displayed on a monitor simulating what an observer would see through a window in a spacecraft. The target replica is coded along one self coordinate axis in such a way that the distance of an elemental area on the target along the axis is capable of being remotely readout by a television camera. A third television camera responsive to the code reads out this information by which the Z-coordinate, relative to the observer, can be calculated, on-line with the scan, for the contents of each picture element of the scene televised by the target camera.
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The suitability of wrought oxide dispersion strengthened (ODS) superalloy sheet for gas turbine engine combustor applications was evaluated. Incoloy MA 956 (FeCrAl base) and Haynes Developmental Alloy (HDA) 8077 (NiCrAl base) were evaluated. Preliminary tests showed both alloys to be potentially viable combustor materials, with neither alloy exhibiting a significant advantage over the other. Both alloys demonstrated a +167C (300 F) advantage of creep and oxidation resistance with no improvement in thermal fatigue capability compared to a current generation combustor alloy (Hastelloy X). MA956 alloy was selected for further demonstration because it exhibited better manufacturing reproducibility than HDA8077. Additional property tests were conducted on MA956. To accommodate the limited thermal fatigue capability of ODS alloys, two segmented, mechanically attached, low strain ODS combustor design concepts having predicted fatigue lives or = 10,000 engine cycles were identified. One of these was a relatively conventional louvered geometry, while the other involved a transpiration cooled configuration. A series of 10,000 cycle combustor rig tests on subscale MA956 and Hastelloy X combustor components showed no cracking, thereby confirming the beneficial effect of the segmented design on thermal fatigue capability. These tests also confirmed the superior oxidation and thermal distortion resistance of the ODS alloy. A hybrid PW2037 inner burner liner containing MA956 and Hastelloy X components was designed and constructed.
The ability of coatings to provide at least a 2X improvement in particulate erosion resistance for steel, nickel and titanium compressor airfoils was identified and demonstrated. Coating materials evaluated included plasma sprayed cobalt tungsten carbide, nickel carbide and diffusion applied chromium plus boron. Several processing parameters for plasma spray processing and diffusion coating were evaluated to identify coating systems having the most potential for providing airfoil erosion resistance. Based on laboratory results and analytical evaluations, selected coating systems were applied to gas turbine blades and evaluated for surface finish, burner rig erosion resistance and effect on high cycle fatigue strength. Based on these tests, the following coatings were recommended for engine testing: Gator-Gard plasma spray 88WC-12Co on titanium alloy airfoils, plasma spray 83WC-17Co on steel and nickel alloy airfoils, and Cr+B on nickel alloy airfoils.
Control problems in developing force feedback control to use in remotely connecting, disconnecting, and reconnecting the umbilical fuel lines of the Space Shuttle Vehicle are discussed. A docking protocol is proposed, indicating the required role of force feedback. The use of active force feedback control is examined and performance requirements and experimental results are given. A single degree-of-freedom force feedback model is presented and the application of classical control compensation techniques to the force control loop to increase flexibility is considered. In addition, possible modifications to the controller and plans for future research are discussed.
Robotic applications at Kennedy Space Center are unique and in many cases require the fime positioning of heavy loads in dynamic environments. Performing such operations is beyond the capabilities of an off-the-shelf industrial robot. Therefore Robotics Applications Development Laboratory at Kennedy Space Center has put together an integrated system that coordinates state of the art robotic system providing an excellent easy to use testbed for NASA sensor integration experiments. This paper reviews the ways of improving the dynamic response of the robot operating under force feedback with varying dynamic internal perturbations in order to provide continuous stable operations under variable load conditions. The goal is to improve the stability of the system with force feedback using the adaptive control feature of existing system over a wide range of random motions. The effect of load variations on the dynamics and the transfer function (order or values of the parameters) of the system has been investigated, more accurate models of the system have been determined and analyzed.
The performance of candidate erosion resistant airfoil coatings installed in ground tested experimental JT8D and JT9D engines and subjected to cyclic endurance at idle, takeoff and intermediate power conditions has been evaluated. Engine tests were terminated prior to the scheduled 1000 cycles of endurance test due to high cycle fatigue fracture of the Gator-Gard plasma sprayed 88WC-12Co coating on titanium alloy airfoils. Coated steel (AMS5616) and nickel base alloy (Incoloy 901) performed well in both engine tests. Post test airfoil analyses consisted of binocular, scanning electron microscope and metallographic examinations.
The suitability of wrought oxide dispersion strengthened (ODS) superalloy sheet for gas turbine engine combustor applications was evaluated. Two yttria (Y2O3) dispersion strengthened alloys were evaluated; Incoloy MA956 and Haynes Development Alloy (HDA) 8077 (NiCrAl base). Preliminary tests showed both alloys to be potentially viable combustor materials, with neither alloy exhibiting a significant advantage over the other. MA956 was selected as the final alloy based on manufacturing reproducibility for evaluation as a burner liner. A hybrid PW2037 inner burner liner containing MA956 and Hastelloy X components and using a louvered configuration was designed and constructed. The louvered configuration was chosen because of field experience and compatibility with the bill of material PW2037 design. The simulated flight cycle for the ground based engine tests consisted of 4.5 min idle, 1.5 min takeoff and intermediate conditions in a PW2037 engine with average uncorrected combustor exit temperature of 1527 C. Post test evaluation consisting of visual observations and fluorescent penetrant inspections was conducted after 500 cycles of testing. No loss of integrity in the burner liner was shown.
Live footage shows the lifting of the external tank to the Endeavour orbiter system of STS-99 in the Vehicle Assembly Building (VAB).
Footage shows close-up shots of the SOHO spacecraft in the Spacecraft Assembly and Encapsulation Facility (SAEF-2).
A gasket assembly for securing a pair of surface together wherein an electrically conductive gasket base having a central opening is provided with a pair of layers secured to opposite sides of the gasket base, with the layers being a fusible alloy, a brazing alloy or a synthetic, thermoplastic material which will melt, without degrading, when the gasket base is heated. The surfaces may be secured to each other by a plurality of bolts to squeeze the gasket assembly there between or by some other clamping means. An electrical current is passed through the gasket base to heat it to a temperature sufficient to melt the layers to seal the surfaces to opposite sides of the gasket base.
A study was performed to determine if a Design of Experiments (DOE)/Response Surface Methodology could be applied to on-orbit thermal analysis and produce a set of Response Surface Equations (RSE) that accurately predict vehicle temperatures. The study used an integrated thermal model of the International Space Station and the Orion Outer mold line model. Five separate factors were identified for study: yaw, pitch, roll, beta angle, and the environmental parameters. Twenty external Orion temperatures were selected as the responses. A DOE case matrix of 110 runs was developed. The data from these cases were analyzed to produce an RSE for each of the temperature responses. The initial agreement between the engineering data and the RSE predictions was encouraging, although many RSEs had large uncertainties on their predictions. Fourteen verification cases were developed to test the predictive powers of the RSEs. The verification showed mixed results with some RSE predicting temperatures matching the engineering data within the uncertainty bands, while others had very large errors. While this study to not irrefutably prove that the DOE/RSM approach can be applied to on-orbit thermal analysis, it does demonstrate that technique has the potential to predict temperatures. Additional work is needed to better identify the cases needed to produce the RSEs
This study is an extension of previous work to evaluate the applicability of Design of Experiments (DOE)/Response Surface Methodology to on-orbit thermal analysis. The goal was to determine if the methodology could produce a Response Surface Equation (RSE) that predicted the thermal model temperature results within +/-10 F. An RSE is a polynomial expression that can then be used to predict temperatures for a defined range of factor combinations. Based on suggestions received from the previous work, this study used a model with simpler geometry, considered polynomials up to fifth order, and evaluated orbital temperature variations to establish a minimum and maximum temperature for each component. A simplified Outer Mold Line (OML) thermal model of the Orion spacecraft was used in this study. The factors chosen were the vehicle's Yaw, Pitch, and Roll (defining the on-orbit attitude), the Beta angle (restricted to positive beta angles from 0 to 75), and the environmental constants (varying from cold to hot). All factors were normalized from their native ranges to a non-dimensional range from -1.0 to 1.0. Twenty-three components from the OML were chosen and the minimum and maximum orbital temperatures were calculated for each to produce forty-six responses for the DOE model. A customized DOE case matrix of 145 analysis cases was developed which used analysis points at the factor corners, mid-points, and center. From this data set, RSE s were developed which consisted of cubic, quartic, and fifth order polynomials. The results presented are for the fifth order RSE. The RSE results were then evaluated for agreement with the analytical model predictions to produce a +/-3(sigma) error band. Forty of the 46 responses had a +/-3(sigma) value of 10 F or less. Encouraged by this initial success, two additional sets of verification cases were selected. One contained 20 cases, the other 50 cases. These cases were evaluated both with the fifth order RSE and with the analytical model. For the maximum temperature predictions, 12 of the 23 components had all predictions within +/-10 F and 17 were within +/-20 F. For the minimum temperature predictions, only 4 of the 23 components (the four radiator temperatures), were within the 10 F goal. The maximum temperature RSEs were then run through 59,049 screening cases. The RSE predictions were then filtered to find 55 cases that produced the hottest temperatures. These 55 cases were then analyzed using the thermal model and the results compared against the RSE predictions. As noted earlier, 12 of the 23 responses were within +/-10 F at 17 within +/-20 F. These results demonstrate that if properly formulated, an RSE can provide a reliable, fast temperature prediction. Despite this progress, additional work is needed to determine why the minimum temperatures responses and 6 of the hot temperature responses did not produce reliable RSEs. Recommend focus areas are the model itself (arithmetic vs. diffusion nodes) and seeking consultations with statistical application experts.
To meet cost and safety objectives, space missions that involve proximity operations between two vehicles require a high level of autonomy to successfully complete their missions. The need for autonomy is primarily driven by the need to conduct complex operations outside of communication windows, and the communication time delays inherent in space missions. Autonomy also supports the goals of both NASA and the DOD to make space operations more routine, and lower operational costs by reducing the requirement for ground personnel. NASA and the DoD have several programs underway that require a much higher level of autonomy for space vehicles. NASA's Space Launch Initiative (SLI) program has ambitious goals of reducing costs by a factor or 10 and improving safety by a factor of 100. DARPA has recently begun its Orbital Express to demonstrate key technologies to make satellite servicing routine. The Air Force's XSS-ll program is developing a protoflight demonstration of an autonomous satellite inspector. A common element in space operations for many NASA and DOD missions is the ability to rendezvous, inspect anclJor dock with another spacecraft. For DARPA, this is required to service or refuel military satellites. For the Air Force, this is required to inspect un-cooperative resident space objects. For NASA, this is needed to meet the primary SLI design reference mission of International Space Station re-supply. A common aspect for each of these programs is an Autonomous Mission Manager that provides highly autonomous planning, execution and monitoring of the rendezvous, inspection and docking operations. This paper provides an overview of the Autonomous Mission Manager (AMM) design being incorporated into many of these technology programs. This AMM provides a highly scalable level of autonomous operations, ranging from automatic execution of ground-derived plans to highly autonomous onboard planning to meet ground developed mission goals. The AMM provides the capability to automatically execute the plans and monitor the system performance. In the event of system dispersions or failures the AMM can modify plans or abort to assure overall system safety. This paper describes the design and functionality of Draper's AMM framework, presents concept of operations associated with the use of the AMM, and outlines the relevant features of the flight demonstrations.
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The Explorer Platform is a Modular Mission Spacecraft: it has several subunits that are designed to be replaced on orbit. The Goddard Space Flight Center Robotics Lab undertook an experiment to evaluate various robotic approaches to replacing one of the units; a large (approximately 1 meter by 1 meter by 0.5 meter) power box. The hardware consists of a Robotics Research Corporation K-1607 (RRC) manipulator mounted on a large gantry robot, a Kraft handcontroller for teleoperation of RRC, a Lightweight Servicing Tool (LST) mounted on the RRC, and an Explorer Platform mockup (EP) with a removable box (MMS) that has fixtures that mate with the LST. Sensors include a wrist wrench sensor on the RRC and Capaciflectors mounted on the LST and the MMS. There are also several cameras, but no machine vision is used. The control system for the RRC is entirely written by Goddard; it consists of Ada code on three Multibus I 386/387 CPU boards doing the real-time robot control, and C on a 386 PC processing Capaciflector data. The gantry is not moved during this experiment. The task is the exchange of the MMS; it is removed and replaced. This involves four basic steps: mating the LST to the MMS, demating the MMS from the EP, mating the MMS to the EP, and demating the LST form the MMS. Each of the mating steps must be preceeded by an alignment to bring the mechanical fixtures within their capture range. Two basic approaches to alignment are explored: teleoperation with the operator viewing thru cameras, and Capaciflector based autonomy. To evaluate the two alignment approaches, several runs were run with each approach and the final pose was recorded. Comparing this to the ideal alignment pose gives accuracy and repeatability data. In addition the wrenches exerted during the mating tasks were recorded; this gives information on how the alignment step affects the mating step. There are also two approaches to mating; teleoperation, and impedance based autonomy. The wrench data taken during mating using these two approaches is used to evaluate them. Section 2 describes the alignment results, section 3 describes the mating results, and finally Section 4 gives some conclusions.